Apparatus for forming and applying stone-simulating wall finishes



A118- 1, 1950 F. L HORNBERGER 2,517,432

APPARATUS FOR FORIING AND PPLYING STONE-SIIULATING 'ALL FINISHES Filed Nov. 20. 1947 FIM :Nm/rox. FLUYU L. HUR/VBEREL? Patented Aug. 1, 1950 APPARATUS FOR FORMING AND APPLYING STONE-SIMULATING WALL FINISHES Floyd L. Hornberger, Akron, Ohio, assignor to Edward J. Miller, Columbus, Ohio Application November 20, 1947, Serial No. 787,122

2 Claims.

This invention relates to apparatus for forming and applying stone-simulating plastic to a surface, and, more particularly, is concerned with molds for shaping and applying cement or other setting plastic material in thin layer form to the surface of a wall.

It has been well known heretofore to form cement in thin molds which produce a stone-like surface on the cement, the formed cement bodies being then applied to a wall surface. For example, the method disclosed and claimed in U. S. Patent No. 1,888,234 has been practiced commercially with great success to remodel an old building or to improve the appearance of a new building by applying to the outer or other walls of a building thin cement layers which in color, shape, and general appearance, closely simulate a much more eX- pensive solid stone construction. However, the apparatus disclosed in the identified U. S. patent, and in companion U. S. Patent No. 1,960,276, is relatively cumbersome, expensive, and difhcult to clean. This apparatus has employed a sheet metal husk which surrounds the mold, with the husk being adapted to be moved from one position to another with respect to the mold to provide flanges when the mold is being iilled with cement, and to allow the anges to move out of, the way when the cement is being applied to a Wall surface. The husks must be cleaned periodically, cement gets between the husk and the mold, and the structure is cumbersome and time consuming to employ.

It has also been proposed, for example, in Patent No. 2,286,531, to employ a rubber flange in conjunction with a mold of the indicated type, but such a rubber flange has been found to be unsatisfactory in that it does not provide adequate strength during the molding operation, and because it interferes with the setting of the formed cement slab.

It is the general object of my invention to avoid and overcome the foregoing and other difficulties of and objections to known molds and apparatus for the indicated purposes by the provision of an improved, relatively inexpensive, simple, easily operated one-piece mold adapted to receive and mold cement or the like in stone-simulating slabs, and to apply the same to a wall or other surface.

Another object of my invention is the provision of a mold having an integral edge flange having its inner surface positioned at oblique angle of between 55 and 80 degrees, thissurface of the flange being groove vented and the flange terminating in a relatively sharp edge.

` The foregoing objects of my invention, and

other objects which will become apparent as the description proceeds, are achieved by the provision of a device including a substantially flat, substantially rectangular base portion having its upper surface shaped to simulate the contour of a stone, or like surface, an upstanding flange surrounding the base and formed integral therewith, the outside of the ange forming substantially a right angle with the base, the inside surface of the flange forming an angle of between about 55 and about 80 degrees with the base, the liange terminating in a relatively sharp upper edge and having a height equal to about twice the thickness of the base, the base having a plurality of air vent openings therethrough, the flange having a plurality of upwardly directed air vent grooves on its inside surface and at the corners of the ange, and a pair of handles associated with the underside of the base.

For a betterunderstanding of my invention, reference should be had to the accompanying drawings, wherein:

Fig. 1 is a perspective view, partly broken away, of a mold -incorporating the principles of the invention; and

Fig. 2 is an inverted end elevationof the mold shown in Fig. 1.

4ln the drawings, the numeral l!! indicates generally the improved mold or apparatus of my invention which includes a substantially flat, substantially rectangular base l2, the upper surface of which is formed with a contour which will simulate a desired surface, usually that of a natural stone, such surface being indicated by the numeral I4.

Surrounding the base I2 is a flange indicated as a whole by the numeral I6, the flange having an outer surface IB formed substantially at right angles to the base, and an inner surface 2U formed at an oblique anglewith the base l2. The inside surface 2l! of the ange I6 should form an angle of between 55 and 80 degrees with the base. The flange I6 is made of a height about twice the thickness of the mold base, and the ange terminates in a relatively sharp upper edge. lt will be understood that the relatively sharp upper edge of the flange is not a cutting edge but is rounded on a small radius. Also, it might be noted that the flange is usually about one-half inch high above the base regardless of the thickness of the base.

A flange constructed as illustrated and described not only serves to provide adequate support during the molding of the cement or other material in the mold, but functions in a particularly satisfactory manner in the application of the formed slab to a wall surface. Specifically, the flange gives sharp definition to the sides of the slab and yet allows even, untilted application thereof to the surface. It is to be noted that the flange i6 is preferably and conveniently formed integral with the base l2 during a single casting operation to achieve a low manufacturing cost simultaneously with good strength and durability.

The base I2 is provided with a plurality of vent openings 22 therethrough, and an important part of the invention is to provide venting grooves 24 on the inside surface 2t of the flange which extend in an upward direction. The flange corners are also formed with upwardly directed venting grooves 26, and with vent holes 21 extending through the base.

One or more handles are associated with the back or underside of the base i2, dependent upon the size of the mold. Usually two handles 28 are provided at longitudinally spaced points on the mold and in transversely directed positions, such handles being positioned in from the ends of the mold approximately one-quarter or so of the length of the mold.

Within the broad concepts of my invention, such handles may take a variety of forms, but I have found that it is usually convenient to support the handles 28 on brackets 30 which are cast integrally with the back or underside of the base It will be understood that the molding and applying apparatus herein described is used sub- Smlly in the manner set forth in the patents I:

identified above, namely, the mold is positioned with the surface i4 uppermost, wax paper is placed over the mold and flanges, coloring powders are scattered on the wax paper, cement is then applied over the powders to ll the mold substantially to the level or slightly greater than the level of the flanges with the excess cement being troweled off or scraped with a curved board which engages with the flanges.

After complete or partial setting of the cement or other plastic, the mold is then lifted by the handles to apply the molded slab to a solid or a plastic-coated wall surface. The mold is very easily maneuvered during this operation to firmly and uniformly apply the slab, and often the mold can be operated so that the relatively sharp flanges will penetrate simultaneously, or alternately if the mold is rocked slightly during application, to engage the hard or solid wall surface beneath any plastic wall coating or surplus cement in the mold to thereby set as gauge means to insure applying the slab in a flat and satisfactory manner to the wall. The relatively sharp anges also act as aligning means for lining up the slab with any marks on the Wall receiving the slab. After the application of the slab the mold is readily removed from the slab and the slab is allowed to set up after which it is finished by the usual procedure of removal of the paper and the pointing up of seams between the slabs in known fashion. The mold is ready for immediate reuse.

From the foregoing, it will be recognized that the various objects of my invention have been achieved by the provision of a relatively simple, inexpensive, easily operated, molding and applying apparatus for stone-like slabs. Improved guide or gauge means are incorporated with the Fil mold which facilitate the slab application and materially assist in and simplify the molding operation also. Venting of all mold parts is excellent and air pockets in the formed material are not experienced. Cleaning of the mold at very frequent intervals is eliminated, as are moving parts which clog or increase the mold cost,

My improved mold can obviously be made in any desired size and shape, and usually the applicator will have a set of variously sized and shaped molds in order to do a variegated, artistic job on any given wall or building.

While in accord with the patent statutes, I have specifically illustrated and described one best known embodiment of my invention, it is to be particularly understood that I am not to be limited thereto or thereby, but that the scope of my invention is dened in the appended claims.

I claim:

l. Apparatus for forming and applying stonesiinulating cement or the like to a surface, coina substantially flat rectangular base portion having its upper surface shaped to simulate the contour of a stone or like surface, said hase portion having a plurality of air vent openings therethrough, certain of said openings being adjacent to the marginal edges of the base; an upstanding flange extending around the marginal edges of the base and formed integral therewith, flange having substantially uniform height and the outside surface thereof forming a right angle with the the inside surface of the flange forming an acute angle of between 10 and degrees with said outside surface thereof and converging toward the upper extremity of the so as to produce a relatively sharp upper edge on the flange, said flange having a plurality ci upwardly directed air vent grooves on its inside surface, several of which communicate with the air vent openings in the which are adjacent to the marginal edges of the base; and handle means attached to the underside of the base.

2. A tool for applying stone-simulating cement or the like to a surface, comprising: a relatively flat rectangular base portion having an upper surface formed to impart the desired surface configuration to the cement, said base having a plu.- rality of air vent openings extending therethrough; a ange of uniform height surrounding the base and extending upwardly therefrom with the frange terminating in a sharp upper edge, the outer surface of the flange forming a right angle with the base and the inside surface of iiange forming an acute angle of between. l@ and 35 degrees with said outer surface thereof, said flange having a plurality of air vent grooves on its inner surface and at its corners, and the base .having other air vent openings therein adjacent to and communicating with the openings at the flange corners; and handle means on the underside of the base.

FLOYD L. HORNBERGER.

REFERENCES @FEED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,061,085 Kolson May 6, i913 1,888,234 Miller Nov. 22, 1932 1,960,276 Miller May 29, 1934 

